CN114905136B

CN114905136B - Axle housing assembly having a spindle and method of manufacture

Info

Publication number: CN114905136B
Application number: CN202210120332.8A
Authority: CN
Inventors: 肯尼思·余; 约瑟夫·梅莱基安; 斯里尼瓦萨·佩鲁马尔·伦加萨米
Original assignee: ArvinMeritor Technology LLC
Current assignee: ArvinMeritor Technology LLC
Priority date: 2021-02-08
Filing date: 2022-02-07
Publication date: 2024-06-07
Anticipated expiration: 2042-02-07
Also published as: US11498361B2; EP4039498A1; BR102022002348A2; CN114905136A; US20220250411A1; EP4039498B1

Abstract

An axle housing assembly and a method of manufacture are disclosed. A friction weld may join the main shaft to the arm portion of the axle housing assembly. An extension weld may encircle the arm portion. The extension weld may extend from the friction weld in a direction that may extend away from the spindle.

Description

Axle housing assembly having a spindle and method of manufacture

Technical Field

The present disclosure relates to an axle housing assembly having a spindle and a method of manufacture.

Background

A system and method for friction welding workpieces is disclosed in U.S. patent No. 9,713,854.

SUMMARY

In at least one embodiment, an axle housing assembly is provided. The axle housing assembly may include an arm portion, a main shaft, a friction weld, and an extension weld. The arm portion may extend about an axis. The spindle may extend from the arm portion. The friction weld may extend about the axis and may join the spindle to the arm portion. The extension weld may encircle the arm portion and may extend from the friction weld in a direction extending away from the main shaft.

In at least one embodiment, a method of manufacturing an axle housing assembly is provided. The method may include friction welding the spindle to an end of an arm portion extending about the axis. The outer curl created when the spindle is friction welded to the arm portion may be removed. An extension weld around the arm portion may be provided after removal of the outer bead. The extension weld may extend from the friction weld in a direction extending away from the main shaft.

Drawings

FIG. 1 is a perspective view of an example of an axle housing assembly.

Fig. 2 is a sectional view taken along a section line X-X, showing an example of the main shaft and arm portions before joining.

Fig. 3 is a cross-sectional view showing the main shaft friction welded to the arm portion.

Fig. 4 is a cross-sectional view of the spindle after removal of the curl created when the spindle is friction welded to the arm portion.

FIG. 5 is an enlarged side view of a portion of the axle housing assembly of FIG. 4.

FIG. 6 is a cross-sectional view of a portion of the axle housing assembly after the addition of an extension weld.

FIG. 7 is a side view of a portion of the axle housing assembly of FIG. 6.

Detailed Description

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Referring to FIG. 1, an example of an axle housing assembly 10 is shown. The axle housing assembly 10 may be part of an axle assembly. The axle assembly may be part of a vehicle driveline that may provide torque to one or more traction wheel assemblies, which may include tires mounted on wheels. The axle assembly may be provided for a vehicle, such as a truck, passenger car, farm equipment, mining equipment, military transport or armed vehicle, or cargo loading equipment for land, air, or marine vessels. In one or more embodiments, the vehicle may include a trailer for transporting cargo.

The axle housing assembly 10 may facilitate mounting the axle assembly to a vehicle. In addition, the axle housing assembly 10 may receive various components of the axle assembly. For example, the axle housing assembly 10 may at least partially receive a differential assembly and one or more axle shafts. In at least one configuration, the axle housing assembly 10 may include a center portion 20, at least one arm portion 22, and at least one spindle 24. The axle housing assembly 10 may also include friction welds 26 and extension welds 28 as best shown in FIG. 7.

Referring to FIG. 1, the center portion 20 may be disposed proximate the center of the axle housing assembly 10. The central portion 20 may define an opening 30 and a cavity 32 that may receive a differential assembly. For example, a differential carrier supporting the differential assembly may be mounted to the central portion 20 such that a portion of the differential carrier may extend through the opening 30 and the differential assembly may be received within the cavity 32. The lower region of the central portion 20 may at least partially define an oil pan portion that may contain lubricant.

One or more arm portions 22 may extend from the central portion 20. For example, the two arm portions 22 may extend in opposite directions from the central portion 20 and away from the cavity 32. The arm portion 22 may be configured to receive a half shaft. For example, the arm portion 22 may have a hollow or tubular configuration that may extend around the respective axle half and may help separate or isolate the axle half from the surrounding environment. The arm portion 22 may also extend about an axis 40. The axle shafts and/or wheels may rotate about an axis 40. The arm portion 22 or a portion thereof may be integrally formed with the central portion 20. Alternatively, the arm portion 22 may be separate from the center portion 20. In such a configuration, each arm portion 22 may be attached to the central portion 20 in any suitable manner, such as by welding or with one or more fasteners.

Referring to fig. 2, an end region of arm portion 22 is shown. Arm portion 22 may include an arm portion end surface 50, an outer side 52, an inner side 54, and an arm portion cavity 56.

The arm portion end surface 50 may be disposed at a distal end of the arm portion 22, which may face away from the central portion 20 and may be disposed opposite the central portion. In at least one configuration, arm portion end surface 50 may extend about axis 40 and may be disposed substantially perpendicular to the axis.

The outer side 52 may face away from the axis 40. The outer side 52 may extend from the arm portion end surface 50 toward the central portion 20 or to the right as viewed from the perspective shown. The outer side 52 may include one or more outer surfaces that may be disposed at different distances from the axis 40. In at least one configuration and as best shown with reference to fig. 2, the outer side 52 may include a first outer surface 60, a second outer surface 62, a tapered surface 64, or a combination thereof. As best shown in fig. 5, one or more swage marks 66 may be provided on the outer side 52.

The first outer surface 60 may extend from the arm portion end surface 50 to the end of the tapered surface 64. In at least one configuration, the first outer surface 60 can have a constant or substantially constant outer diameter.

The second outer surface 62 may be disposed on a side of the tapered surface 64 opposite the first outer surface 60. For example, the second outer surface 62 may extend from an end of the tapered surface 64 disposed opposite the first outer surface 60 toward the central portion 20. In this way, the second outer surface 62 may be spaced apart from the first outer surface 60. The second outer surface 62 may have a larger outer diameter than the first outer surface 60.

The tapered surface 64 may extend between the first outer surface 60 and the second outer surface 62. For example, the tapered surface 64 may extend from an end of the first outer surface 60 to an end of the second outer surface 62. The tapered surface 64 may taper toward the axis 40 in an axial direction extending toward the spindle 24 and arm portion end surface 50, or to the left as viewed from the perspective shown. For example, the tapered surface 64 may become progressively closer to the axis 40 in a direction extending from the second outer surface 62 toward the first outer surface 60.

Referring to fig. 5, one or more swage marks 66 may be provided on the outer side 52 of the arm portion 22. The swage marks 66 may be formed by a tool when the arm portion 22 is shaped or swaged to reduce the diameter of the arm portion 22 near the arm portion end surface 50. For example, during manufacture of the arm portion 22, the outer side 52 of the arm portion 22 may have a substantially constant diameter from the arm portion end surface 50 to the second outer surface 62. A portion of the outer side 52 may be swaged to reduce the outer diameter proximate the arm portion end surface 50 and thereby form the tapered surface 64 and the first outer surface 60. The swage marks 66 may have any suitable configuration. In the illustrated configuration, the swage marks 66 are depicted as pairs of slightly splayed lines that extend in substantially the same direction as the axis 40. Swage marks 66 may indicate where the recess or dent is formed in outer side 52. Alternatively or additionally, the material may rise in a narrow region between a pair of splayed lines or protrude outwardly away from the axis 40 (e.g., a narrow region between convex sides of a pair of swage marks 66 may protrude away from the axis relative to tapered surface 64). Swage marks 66 may be formed in at least a portion of tapered surface 64 and may optionally extend to and may be formed in first outer surface 60, second outer surface 62, or both.

Referring to fig. 2, the medial side 54 may be disposed opposite the lateral side 52. In this way, the inner side 54 may face the axis 40. The inner side 54 may extend from the arm portion end surface 50 to the central portion 20 and may at least partially define an arm portion cavity 56.

The arm portion cavity 56 may extend from the cavity 32 of the central portion 20 shown in fig. 1 to the arm portion end surface 50. The axle shafts may extend through the arm portion cavity 56.

Referring to fig. 1 and 2, the arm portion 22 may be provided with a brake mounting flange 70 to facilitate the mounting of the brake assembly. The brake mounting flange 70 may be positioned axially or along the axis 40 between the center portion 20 and the arm portion end surface 50. For example, the brake mounting flange 70 may surround and may be disposed on the second outer surface 62. The brake mounting flange 70 may be secured to the arm portion 22 in any suitable manner (e.g., by one or more welds 72).

Referring to fig. 1-3, the spindles 24 may extend from the respective arm portions 22. For example, the spindle 24 may extend along or about the axis 40 and may extend from the arm portion end surface 50 in a direction extending away from the central portion 20. The spindle 24 may be configured to support a hub of a wheel end assembly. For example, the main shaft 24 may be received within one or more wheel bearings, which may rotatably support the hub. The hub may rotate about the axis 40 and may facilitate mounting of a wheel on which the tyre may be disposed. In at least one configuration, the spindle 24 may include a first spindle end 80, a second spindle end 82, a spindle outer side 84, a spindle inner side 86, a spindle bore 88, or a combination thereof. These features are best shown with reference to fig. 2 and 3.

The first spindle end 80 (which may also be referred to as a first spindle end surface) may be disposed proximate the arm portion 22. For example, the first spindle end 80 may face and may contact or engage the arm portion end surface 50 of the arm portion 22. In at least one configuration, the first spindle end 80 may be disposed substantially parallel to the arm portion end surface 50 and may be disposed substantially perpendicular to the axis 40.

The second spindle end 82 (which may also be referred to as a second spindle end surface) may be disposed opposite the first spindle end 80. In this way, the second spindle end 82 may face away from the arm portion 22. The second spindle end 82 may be a distal end surface of the axle housing assembly 10.

The spindle outer side 84 may face away from the axis 40. The spindle outer side 84 may extend from the first spindle end 80 to the second spindle end 82 and may include one or more outer surfaces, which may be disposed at different distances from the axis 40. One or more wheel bearings may engage or contact the spindle outer side 84.

The spindle inner side 86 provided when the spindle 24 is hollow may be disposed opposite the spindle outer side 84. In this way, spindle inner side 86 may face axis 40. The spindle inner side 86 may extend from the first spindle end 80 to the second spindle end 82 and may at least partially define a spindle bore 88.

Referring to fig. 2-7, an example of a method of manufacturing the axle housing assembly 10 is shown. Fig. 2 to 4 and 6 are sectional views taken along the section line X-X and the axis 40 in different steps of the manufacturing process. Fig. 5 and 7 are side views, rather than cross-sectional views.

Referring to fig. 2, the spindle 24 and a portion of the arm portion 22 are shown prior to attaching the spindle 24 to the arm portion 22.

Referring to fig. 3, the spindle 24 is shown after being friction welded to the arm portion 22. During friction welding, at least one of the spindle 24 and the arm portion 22 may be rotated about the axis 40, and then the first spindle end 80 may be engaged with the arm portion end surface 50 under axial load. Friction between the first spindle end 80 and the arm portion end surface 50 may generate heat that may partially melt the spindle 24 and the arm portion 22, thereby creating the friction weld 26. The friction weld 26 may extend continuously about the axis 40 and may join the spindle 24 to the arm portion 22.

Axial loads during friction welding may create a curl on arm portion 22 and spindle 24. A bead (which may also be referred to as a friction weld bead) may extend outwardly from the friction weld 26 and may protrude from the arm portion 22 and the spindle 24. For example, the first outer curl 90 and the first inner curl 92 can be created primarily from the arm portion 22, while the second outer curl 100 and the second inner curl 102 can be created primarily from the spindle 24. The first and second outer beads 90, 100 may extend away from the axis 40 and may curl away from each other. The first and second inner curls 92, 102 may extend toward the axis 40, may be disposed within the arm portion cavity 56 and spindle bore 88, and may curl away from each other. The first and second outer beads 90, 100 and the first and second inner beads 92, 102 may extend in a continuous loop about the axis 40 and may increase in size as friction welding proceeds. When friction weld 26 is complete, the rotation and axial loading of spindle 24 and/or arm portion 22 may terminate.

Referring to fig. 4 and 5, after the spindle 24 is friction welded to the arm portion 22, one or more of the curls may be removed. For example, a cutting tool may sever the first and second outer beads 90, 100 from the friction weld 26, while another cutting tool may sever the first and second inner beads 92, 102 from the friction weld 26. Removal of the first and second outer beads 90, 100 may create an annular surface 110. The annular surface 110 may extend continuously about the axis 40. Furthermore, the annular surface 110 may be disposed substantially parallel to the axis 40.

In at least one configuration, the annular surface 110 may protrude outwardly relative to the arm portion 22, the spindle 24, or both, or in a direction extending away from the axis 40. For example, the annular surface 110 may be disposed farther from the axis 40 than an adjacent portion of the outer side 52 (e.g., the first outer surface 60), may be disposed farther from the axis 40 than an adjacent portion of the outer spindle side 84, or both. In this way, friction weld 26 may cooperate with arm portion 22 to create recess 112. The recess 112 may surround the arm portion 22 and may extend in the axial direction between the friction weld 26 and the second outer surface 62. In at least one configuration, the recess 112 may be defined by the friction weld 26, the first outer surface 60, and at least a portion of the tapered surface 64.

As best shown in fig. 5, removal of the outer bead may create at least one uneven serrated edge 120 on the friction weld 26. Serrated edge 120 may surround axis 40 and may be disposed at an end of annular surface 110 facing arm portion 22. Serrated edge 120 and/or swage mark 66 may create a high stress concentration zone in arm portion 22 between serrated edge 120 and brake mounting flange 70 where one or more fatigue cracks may be easily created or formed. Removing more material from the friction weld 26 adjacent to the surface of the arm portion 22 and/or the main shaft 24 may eliminate the serrated edge 120 and create a smoother transition, but may also reduce the outer diameter and wall thickness of this area, which may reduce the strength of the axle housing assembly 10. Instead of removing material to eliminate serrated edge 120, an extension weld 28 is provided.

Referring to fig. 6 and 7, an extension weld 28 is provided after removal of the outer bead. The extension welds 28 may be provided by any suitable welding technique or addition fusion technique (which may add sufficient material to form the extension welds 28). For example, the extension weld 28 may be provided by Metal Inert Gas (MIG) welding.

The extension weld 28 may continuously encircle or extend around the arm portion 22. Further, the extension weld 28 may not extend to the inner side 54 of the arm portion 22 and, thus, may be spaced apart from the arm portion cavity 56. As such, the extension weld 28 may extend partially, but not fully, through the arm portion 22. Further, the extension weld 28 may extend from the friction weld 26 in an axial direction in a direction that may extend away from the main shaft 24. For example, the extension weld 28 may extend from the friction weld 26 to the tapered surface 64, and optionally to the second outer surface 62. The extension welds 28 may partially or completely fill the recess 112, as best shown by comparing fig. 5 and 6. Accordingly, the extension weld 28 may increase the wall thickness or effective wall thickness of the arm portion 22 between the friction weld 26 and the tapered surface 64 or between the friction weld 26 and the second outer surface 62. The extension welds 28 may or may not be aligned with the annular surface 110. For example, in one or more configurations, the extension weld 28 or a portion thereof may extend farther from the axis 40 than the annular surface 110.

The extension weld 28 may consume the serrated edge 120. In this way, the extension weld 28 may eliminate the serrated edge 120 without employing machining operations to remove material from the arm portion 22, the spindle 24, or the friction weld 26, and may reduce or eliminate stress concentrations associated with the serrated edge 120 in the arm portion 22, thereby preventing or reducing associated fatigue cracks.

Referring to fig. 7, the extension weld 28 may also partially or fully cover or encapsulate one or more swage marks 66. For example, the extension weld 28 may fill or partially fill the swage mark configured as an indentation, which may increase the effective wall thickness adjacent to the swage mark 66, and may reduce stress concentrations associated with the swage mark 66 in the arm portion 22, thereby preventing or reducing associated fatigue cracks.

The axle housing assembly described above may have better fatigue performance and improved durability and life expectancy compared to an axle housing assembly without an extended weld. The increased durability may allow the axle housing assembly to accommodate or withstand higher loads. Further, rather than redesigning the axle housing assembly and incurring the associated design, testing and tooling costs, the existing axle housing assembly design may be used to accommodate higher loads, and expensive or heavier materials are not used. These advantages may be significant when designing a new axle housing assembly is not financially viable, such as when the manufacturing volume of the axle housing assembly is low.

While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Furthermore, features of the various implemented embodiments may be combined to form further embodiments of the invention.

Claims

1. An axle housing assembly comprising:

an arm portion extending about an axis;

a spindle extending about the axis and extending from the arm portion;

a friction weld extending about the axis and joining the spindle to the arm portion; and

An extension weld surrounding the arm portion and extending from the friction weld in a direction extending away from the main shaft, wherein the extension weld includes additional material added to the arm portion and does not include curled edge material extending from the friction weld.

2. The axle housing assembly of claim 1, wherein said friction weld protrudes from said main shaft.

3. The axle housing assembly of claim 1, wherein said extension weld at least partially fills a swage mark in said arm portion extending from an outer side of said arm portion toward said axis.

4. The axle housing assembly of claim 3, wherein said arm portion has a tapered surface facing away from said axis and tapering toward said axis in an axial direction extending toward said main axle, wherein said swage marks extend from said tapered surface toward said axis.

5. The axle housing assembly of claim 4, wherein said extension weld extends axially from said friction weld to said tapered surface.

6. The axle housing assembly of claim 4, wherein the tapered surface extends from a first outer surface of the arm portion to a second outer surface of the arm portion, the first outer surface extending from the friction weld to the tapered surface and having a smaller diameter than the second outer surface, wherein the extension weld extends axially from the friction weld to the second outer surface.

7. The axle housing assembly of claim 4, wherein the extension weld increases a wall thickness of the arm portion between the extension weld and the tapered surface.

8. A method of manufacturing an axle housing assembly, the method comprising:

Friction welding a spindle to an arm portion end surface of an arm portion, the arm portion end surface extending about an axis;

Removing an outer curl created when the spindle is friction welded to the arm portion, wherein removing the outer curl includes severing the outer curl from a friction weld; and

After removal of the outer bead, an extension weld is provided around the arm portion, wherein the extension weld extends from the friction weld in a direction extending away from the spindle.

9. The method of claim 8, wherein the extended weld is provided by Metal Inert Gas (MIG) welding.

10. The method of claim 8, wherein the arm portion and the extension weld extend from the friction weld in the direction extending away from the main shaft.

11. The method of claim 8, wherein the extension weld at least partially fills a swage mark in the arm portion extending from an outside of the arm portion toward the axis.

12. The method of claim 11, wherein the arm portion has a tapered surface facing away from the axis and tapering toward the axis in an axial direction extending toward the spindle, and wherein the swage mark extends from the tapered surface.

13. The method of claim 12, wherein the tapered surface extends from a first outer surface of the arm portion to a second outer surface of the arm portion, the first outer surface extending from the friction weld to the tapered surface and having a smaller diameter than the second outer surface, wherein the extension weld extends from the friction weld to the second outer surface.

14. The method of claim 12, wherein the extension weld increases a wall thickness of the arm portion between the extension weld and the tapered surface.

15. The method of claim 12, wherein the extension weld fills a recess surrounding the arm portion and extending between the extension weld and the tapered surface.

16. The method of claim 8, wherein removing the outer bead creates an annular surface that extends continuously about the axis and is disposed substantially parallel to the axis.

17. The method of claim 8, wherein the friction weld protrudes from the spindle and from the arm portion after removing the outer bead, and wherein removing the outer bead creates an annular surface that extends continuously about the axis such that the annular surface is disposed farther from the axis than the spindle and an adjacent portion of the arm portion.

18. The method of claim 17, wherein removing the external bead creates a serrated edge on the friction weld, and wherein the extension weld consumes the serrated edge.

19. The method of claim 18, wherein the serrated edge surrounds the axis and is disposed at an end of the annular surface facing the arm portion.

20. The method of claim 18, wherein consuming the serrated edge and at least partially filling the swage mark in the arm portion reduces stress concentrations in the arm portion.